Extrusion control



T. J. RHODES EXTRUSION CONTROL sept. 4, 1951 Filed Jan. 26, 1949 Patented Sept. 4, 1951 UNITED STATES PATENT OFFICE EXTRUSION CONTROL Application January 2s, 1949, serial No. 72,989

This invention relates to. an improved method and apparatus for extruding rubber and the like, which involves changing the extrusion pressure in response to a change in a dimension of the extruded product, whereby a product having a substantially uniform transverse cross-section throughout its length is obtained while deviations from the desired rate of extrusion are maintained at a minimum.

In extruding rubber, plastics, and similar' materials, itis conventional to force or squeeze the stock, usually at an elevated temperature, by means of a screw feeder, through a diev having the desired shape. As the rubbery stock emerges from the die, it tends to recover elastically, that is, to increase to a size larger than the die opening. Since the magnitude of the recovery depends, among' other things, on the viscosity of the stock, any change in the viscosity of the stock passing through the extruder results in a corresponding change in the dimensions cf the.

finished product unless a compensatory'change in pressure on the stock in `the die opening occurs. Such changes in the viscosity of the stock may be due to various factors, such as variations of temperature in the extru'der, changes in the character of the raw materials, or changes in the method of mixing the batch. The resulting changes in dimensions of the extruded article give rise to considerable wastage of material in the form of articles which are unacceptable by reason of being undersize, or in the form of articles which are unnecessarily oversize, such as preforms Ifor molding operations, wherein the excess material is Wasted as flash.

One expedient which has been used in an attempt to extrude articles of relatively: constant dimensions is to vary the tension, on thestock as it leaves the extruder die, byy regulating the speed of travel of the article away from the extrusionorice. Another expedient which has been usedis to vary the speed of rotation of the `feeding screw in the extruder.

of extrusion from the nozzle orice necessarily varies at the same time. -Such variation in the extrusion rate is undesirable becauseI it necessitates changing the rate at which material is fed to the extruder. A fairly constant rate of extrusion is also necessary for efcient and economic factory operation, which requires proper scheduling of mill mixing operations to t the rate at which stock is consumedrby the ex truder, and which requires proper scheduling of molding or other operations to fit the rate of production of extruded preiorins.

15 trance to the extrusion die.

These methods have the serious disadvantage that the rate (Cl. 18l2) 2 The'principal object of the present invention is to provide a method and apparatus for extruding products of constant dimensions with a minimum of variation in the extrusion rate.

5 My invention comprises a controlled pressure lo controlled by a dimension of the extruded ar-- The essential parts of the extruder throtticle. tling means include a nozzle section, that is, a

throat or tapered section in the extruder bar' rel, located immediately adjacent to the en- Within the said throat or tapered section, there is provided a cooperating nozzle core. These two cooperating nozzle members denne a throttling passageway through which the plastic stock passes from the By moving one oi these nozzle members axially relative to the other member, the area of the throttling passageway therebetween may be varied, with consequent variation in the pressure at which the stock is passed into the die. For example, in a preferred form of the invention, I employ an extruder having an adjustable feed ing screw which is tapered and which rotates in a correspondingly tapered barrel.

While the tapered screw serves as a nozzle core adjustable within the outer nozzle member. The tapered screw and tapered barrel are employed in combination with means to detect a depar- 35 ture of a dimension ofthe shaped extruded product from a predetermined value, and associated means to vary axially the position of the tapered feeding screw in the tapered barrel in response to the detecting means. Varying the axial posi- 40 tion of the tapered screw member with respect to the barrel results in a throttling or nozzle effect which produces a change in the pressure at which the stock is forced into the extrusion orice, or shaping die. This change of extru- 4-'5 sion pressure produces, in turn, a change in `the recovery of the stock as it emerges from the shaping die. In this Way, I am able, by controlling the extrusion pressure, to control the amount or" elastic recovery of the stock on emerging from the shaping die, and by so controlling the recovery of the stock, I am able to maintain the size of the extruded article substantially constant, even though the viscosity of the stock be- 55 ing extruded is changing.

An apparatus embodying and adapted to demextrusion chamber into the extrusion orifice.V

The tapv 30 ered barrel serves as an outer nozzle member,

taken on the line 2 2 of Fig. 1, and showing in elevation a part of the dimension-measuring means; and y Fig. 3 is a side elevation in section of a portion of an extruder illustrating amodication of the invention.

With the extruder shown in the drawing, any* departure of a dimension of the extruded article from the desired value results in an automatic corrective axial adjustment of the position of the extruder screw. Thus', if the viscosity of the stock passing through the extruder suddenly increases for any reason, the extruded article will begin to run over-size due to the fact that the recovery of the stock, or the increase in size of the stock on emerging from the extruder die, is relatively greater for high viscosity stock. The dimension-measuring means will detect this departure from normal size and the associated screw-positioning meanswill cause the tapered screw to move back slightly along its axis, thus increasing the clearance between the screw and l the tapered housing. This increase in the clearance between the feed screw and the housing causes, as mentioned previously, a decrease in Turning now to the detailsof the apparatus,

Fig.V 1 of the drawing shows an extruder supported on a suitable stand I6. The extruder has a tapered feeding screw II for forcing stock through a die I2 having the desired shape. 'I'he feeding screw is rotatably supported within a tapered barrel or stuffer chamber I3, which has a hopper I4 at its entrance end into which the stock to be extruded is fed. The tapered feeding screw is rotated by a suitable motor I 5 which is connected to a pulley i6 on the shaft Il of the screw by a belt I8. The end of the feeding screwV shaft rotates in a suitable ball thrust bearing I9 Which is adapted to be moved backward and forward to change the axial position of the tapered feeding screw with respect to the tapered barrel I3. This backward and forward adjustment is imparted through an arm which is attached to the supporting stand of the machine by a fulcrum 2|, and which is positioned by a pneumatically actuated diaphragm 22 through a connecting rod 23 sliding in a bearing 24. The upper end of the fulcrumed arm 29 is connected to the screw shaft I7 through the thrust bearing I9, and the lower end of the arm is pivotally attached at 25 to the connecting rod 23. The diai phragm 22 acts against a compression spring 26, which resists the thrust of the screw II and tends to return the diaphragm to its original position as the pneumatic Y pressure on the diaphragm is decreased.

Thepneumatic pressure which actuates the diaphragm, and thus controls the position of the tapered screw, is supplied through a pipe 21 connected to a pneumatic controller `28 which may be of any conventional construction, and which is indicated diagrammatically in the drawing. The pneumatic controller is actuated by a dimension-measuring or detecting means which is adapted to detect a change in thickness of the vextruded product 29 after it emerges from the Y extruder die I2.

In the embodiment of the invention illustrated, the extruded product 29 is a tire tread, the crosssectional shape of which is shown in Fig. 2. The tread is carried away from the extruder, as it is produced, by a conveyor belt 39 which rides on rollers 3I and is driven at the desired speed by any suitable means (not shown) The dimensionmeasuring means shown comprises a small arm 32, one end oi which rides or iioats on a selected part of the extruded product on a small roller 33. The arm 32 is adapted to move up or down about a fixed pivotal supporting connection 34 as the thickness of the extruded tread 29 changes. One end of a wire 35 is connected to the pivoted arm 32 through an adjustable block 36.

ably adjusted along the arm 32. The adjustable blockk 36 may be moved back and forth on the arm-32 by turning an adjusting screw 35 which is threaded through the block 36 for this purpose` The other end of the Wire 35 is connected to a flapper valve 38, on which the arm 32 exerts more or less pressure, depending on the thickness of the tread 29. Adjustment may be made for extruding other articles of different thickness by loosening a set screw 39 on the end of the pivoted arm 32, permitting the wheel 33' vto be moved up or down to the required height with respect to the arm 32. The pneumatic controller 28 is connected to a suitable constant pressure compressed air supply (not shown) through a pipe 40. When the pressure exerted on the iiapper 38 through the wire 35 is relieved (as it will'be ifthe tread begins to run over-size, thus raising the pivoted arm 32), air is permitted to escape from a nozzle 4I in the controller, thus permitting a spring loaded rel-ay valve 42 controlled by a pneumatic diaphragm 43 to be opened by the action of a spring 44. The nozzle 4I and the pneumatic diaphragm 43 are supplied with relatively low pressure air fromthe main air supply tube 40 through a reducing tube 45. As the valve 42 opens, air is admitted under pressure to the connecting pipe 21, thus actuating the screw positioning diaphragm 22, which makes the desired corrective backward axial throttling adjustment of the tapered feeding screw II through the fulcrumed 3 arm 20. When the tread is running over-size, the desired throttling adjustment of the tapered feeding screw is in a backward direction, in order to increase the clearance between the tapered screw II and the tapered barrel I3, thus reducing the pressure at which the stock is forced into the die,

and consequently reducing the recovery of the The wire 35 Y supports the arm 32 and the roller 33 at a vari-'- able height depending on the position of they adjustable block 36, which is adapted to be slidaccette greater pressure on the dapper 38 in the controller through the connecting wire 35. This restrains the air from escaping from the nozzle 4I, and causes the air pressure on the pneumatic diaphragm 43 to be increased, thus closing off the relay valve 42 and hence reducing the air pressure in the connecting pipe 21 by shutting oil the air supply from pipe and permitting the escape of air from the pipe 21 through a bleed opening `46. This permits the pneumatic screw-positioning diaphragm 22 to be moved by the spring 2E, -thus moving the screw II forward axially in the tapered barrel I3, by means of the fulcrumed arm 20. This reduces the clearance between the tapered feeding screw I I and tapered barrel I3, thus increasing the pressure atwhichthe stock ispassed into the die I2. This increased extrusion pressure results in a corresponding increase in the recovery of the tread 29 as it emerges from the die, thus` compensating for the effect of the low viscosity of the stock, and maintaining the extruded tread at the required size.

From the foregoing, it is seen that the tapered extruder barrel I3' acts as a nozzle, and the tapered screw II acts as a nozzle core adjustable Within said nozzle, to vary the pressure at which the rubber stock is delivered to the shaping die l2.

Small axial adjustments of the position of the tapered screw II in the tapered barrel I3 have only a relatively small effect on the rate at which the stock is extruded, so that my control of the dimensions of the extruded product is effected independently of great changes in the rate of extrusion.

Fig. 3 of the drawing Shows a modification of the invention in which the desired pressure control, or throttling effect, is obtained by using a screw 5l! which is not tapered along its threaded portion 5I but which has a torpedo head 52, that is, a tapered portion, at its delivery end. The screw 5I! rotates in a barrel or cylinder 53 which has at its delivery end a tapered portion 54 corresponding to the torpedo head 52. Thisextruder also has a conventional die for extruding a desired shaped article 5G. The screw 50 is axially adjustable in a suitable manner, such as the man,- ner described in connection with the tapered screw I I of Fig. 1, and there is associated with the extruded article 56 a suitable dimension-detecting and controlling system, such as that shown in Figs. 1 and 2 in association with the extruded tire tread 29.

The operation of this modification of the invention is the same the operation of the embodiment shown in Fig. l. that is, a change in a dimension of the product 56 produces a corrective adjustment in the axial position of the screw 50. This results in a change in the clearance space between the tapered head 52 of the screw, and the tapered throat 54 of the barrel 53, thereby changing the pressure at which the stock is forced into the die 55, and consequently changing the elastic recovery of the extruded article 56 on emerging from the die.

In the modification shown in Fig. 3, instead of moving the screw 50 longitudinally to correct the .size of the extruded strip 55, the tapered end 51 ofthe barrel 53 may be moved axially of the barrel to produce the desired change in the throttling eiect on the plastic stock between the tapered portions 52 and 5d. In such event, the tapered end 5'! of the extruder 'barrel would be actuated by the arm 20 to slide in and out on the barrel 53 in response to the size detecting roller 33 in Fig. l.

It Will be thus noted that, according to the method of this-invention, the pressure at. which the stoel; is extruded is controlled by the above described nozzle or throttling action in such va manner that changes in the elastic` recovery of the stock upon emerging from the die, which re.- sult from changes in the character of the stock, are immediately nulied so as to cause the crosssection of the product emerging from the die to remain substantially normal.

In order that therthrottling action of the tafw pered screw may be effective to produce instantaneously the desired change in pressure onv the stock being fed into the die, the aforesaid cooperating tapered portions of the screw and barrel should be located immediately adjacent to the entrance to the die, that is, there should be no large reservoir of rubber stock located between the tapered throttling space and the shaping die.

The feeding screw employed may be of any desired type. Screws having threads of the `character described in U. `S. Patent 1,892,217, which have yhigh-ly positive feeding characteristics, may be used to advantage, particularly for extruding at high pressures. i

While the invention has been described in detail with respect to apparatus wherein the de.- sired extrusion pressure Vcontrol is obtained by a throttling mea-ns in which the extruder feeding screw serves as the nozzle core, it will be understood that other suitable nozzle constructions-may be employed. The essential requirement is that the extruder be provided with a throttling means at the entrance to the shaping die. The essential parts of the throttling means comprise a tapered nozzle-like portion of the extruder bar,- rel or extrusion chamber, and a cooperating core member, which may be a `*tapered screw, or a f screw with a torpedo head, orany other suitable core member, located within the said nozzle-like portion, the clearance space between the nozzle,- like portion and the cooperating core being adapted to be changed to produce the desired variation in extrusion pressure.

The dimension measuring and controlling means shown in the particular embodiment of the invention which I have illustrated in detail may be replaced by their known mechanical equivalents. Thus, various photo-electric devices which are capable of detecting a change in di.- mensions with great accuracy, and the structure of which is well known, may be used inplace of the riding measuring arm 32. y In place of the pneumatic controller shown diagrammatica-ily.

other controllers, such as electronic controllers, may be used. The essential feature of this part of the invention is that the dimension-measuring means detects changes in the size of the extruded product from a. desired normal, and actupered barrel so as to vary the extrusion pressure in response to changes in size of the extruded product.

Having thus described my invention, what I claim and desirefto protect by Letters Patent is:

"1.' A method'of extruding plastic material by passing the plastic through a diequnder pressure including the steps of continually. measuringv a dimension of the extruded product after passing from the die, and varying the pressure at which the 'plastic is introduced to the die inversely to a variation in the dimension of the extruded product last measured to maintain the size of means to vary the pressure at which the plastic` is passed into the die inversely to a variation in the dimension of the extruded product last measured and thereby maintain the size of the extruded product substantially constant.

3. A method of extruding plastic material by passing the plastic through a die under pressure by means of a feeding screw which has a taper at least at its end portion'and which rotates in a corresponding tapered barrel, including the steps of continually measuring a dimension of the extruded product after passing from the die, and

decreasing the clearance between the said screw and the said barrel when said measurement indicates a decrease in the said dimension and increasing the 'said clearance when said measurement indicates an increase in said dimension, to maintain the size of the extruded product substantially constant..

4. A method of extruding plastic material by passing the plastic through a die under pressure by means of a feeding screw which has a taper at least at its end portion and which rotates in a correspondingly tapered barrel, including the steps of continually measuringv a dimension of the extruded product after passing from the die, and axially adjusting the clearance between the tapered portion of the screw and the barrel to decrease said clearance when said measurement is undersize, and to increase said clearance when said measurement is oversize, to maintain the size of the extruded product substantially .constant.v

;A method of extruding plastic material by passing the plastic through a die under pressure by means of a tapered feeding screw rotating in a. tapered barrel, including the steps of continually measuring a dimension of the extruded productafter passing from the die, and adjusting the relative position of said screw and barrel to decrease the clearance therebetween when said dimension isfundersize, and to increase' said clearance when said dimension is oversize to regulate the# pressure at which the plastic is fed into the dieywhereby the size of the extruded product is maintained substantially constant.

6.111 an apparatus for extruding Aa product of uniform size, the combination of a shaping die, means for forcing plastic' material under pressure intoj the shaping die, means for regulating the 7. In an apparatus for extruding a product of uniform size, the combination of an extrusion' chamber having a shaping die at the dischargev end.' thereof, means for forcing plastic material from the extrusion chamber into the die.' a'

tapered nozzle section in said extrusion chamber at'the entrance to the die, a cooperating nozzle coreV within'the tapered nozzle section, means for varying the clearance between said nozzle core and said tapered nozzle section to regulate the pressure at which the plastic material is forced into the die, means for detecting a variation in a dimension of the cross-section of the extruded product, and means responding to said dimension-detecting means for controlling the aforesaid' clearance-varying means to'thereby cause the product subsequently extruded tohave a norpressure at which the aforesaid means forces the plastic material into the die, means for detecting a variation in a dimension ofthe cross-section of thefsaid extruded product, and means responding to said `dimension-detecting means for controlling the aforesaid pressure regulating means to thereby cause the product subsequently extruded to have a. normal cross-section.

mal cross-section.

8. In an apparatus for extruding a product of uniform size, the combinationl of a shaping die, means for forcing plastic material under pressure into the die, said means including a cooperating screw and barrel having an adjustable throttling section at the entrance 'to the die to regulate the pressure at which plastic material is delivered thereto, means for detecting a variation in av dimension of the cross-section of the said vextruded product, and control means responsive to saiddimension-detecting means for controlling the aforesaid throttling section to thereby cause the product subsequently extruded for adjusting the clearance between'the feeding screw and the barrel, means for detecting a variation in a dimension of the cross-section ofsaid productgand means responding to said detecting means for adjusting the relative position of said screw and said barrel to thereby cause said product subsequently extruded to have a normal cross-section.

10.'An extrusion apparatus for extruding a product of'uniform sizecomprising an axially adjustable feeding screw tapered at least at its end portion, a correspondingly tapered barrel in which said feeding screw rotates, a shaping die through which plastic material may be forced under pressure from the barrel by the screw,y

means connected to the screw for axially adjusting the position of the screw in the barrel, means for detecting a departure of a dimension of the cross-section of the extruded product from a predeterminednormal, and control means responding to said dimension-detecting( means for axially adjusting said screw in said barrel to thereby cause said product subsequently extruded to have a normal cross-section.

11. An extrusion apparatus for extruding. a product of uniform size comprising an axially adjustable tapered feeding screw, a correspondingly tapered barrel in which said feeding screw rotates, a shaping die through which plastic material may be forced under pressure from the barrel by the screw, a pressure-actuated diaphragm connected to the screw for axially adjusting the position of the screw in the barrel, means for detecting a departure of a dimension of the cross-section of the extruded product from a predetermined normal, and a controller re- 9 sponding to said detecting means for translating a signal from said dimension-detecting means into a change of pressure on said pressure-actuated diaphragm, Whereby a change in a dimension of the extruded product results in a corrective axial adjustment in the position of the screw in the barrel.

THOMAS J. RHODES.

REFERENCES CITED UNITED STATES PATENTS Number Name Date Kaiser et al Apr. 14, 1925 Brown Jan. 22, 1935 Rankin July 14, 1942 Ryan Mar. 20, 1945 MacMillin ket al Dec. 3, 1946 

